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Abstract:

Sound muffling flooring underlay tile systems using sonic foam-enhanced
underlay board may comprise a sound-muffling tile assembly for
installation underneath a floor surface to help minimize sound transfer
between living areas and to provide increased insulation. The
sound-muffling tile assembly may comprise a flooring base member, a
cushioning film layer, and a fastener for securing the flooring base
member to the cushioning film layer. In one embodiment of the present
invention, the cushioning film layer may comprise a foam substance
comprising an open-cell structure. In addition to actively dampening
sound waves that travel through the open-cell structure of the foam
substance, the cushioning film layer provides a floated surface for the
floor above the sound-muffling tile assembly when installed.

Claims:

1. A sound-muffling tiling system for installing on a planar surface
comprising: at least one sound-muffling tile assembly comprising; at
least one flooring base member; at least one sound-absorbing, insulating,
and cushioning film layer; and at least one fastener; wherein said at
least one flooring base member and said at least one sound-absorbing,
insulating, and cushioning film layer comprise approximately identical
dimensions; wherein said sound-absorbing, insulating, and cushioning film
layer serves to provide a floating and leveled surface; wherein said
flooring base member and said sound-absorbing, insulating, and cushioning
film layer are secured together via said at least one fastener; and
wherein said sound-muffling tile assemblies are installable adjacent to
one another on said planar surface to absorb sound thereby serving to
minimize sound propagation between living areas.

2. The sound-muffling tiling system of claim 1, wherein said
sound-absorbing, insulating, and cushioning film layer comprises an open
cell structure.

3. The sound-muffling tiling system of claim 2, wherein said
sound-absorbing, insulating, and cushioning film layer comprises
reticulated foam.

4. The sound-muffling tiling system of claim 1, wherein said
sound-absorbing, insulating, and cushioning film layer comprises
closed-cell foam.

5. The sound-muffling tiling system of claim 4, wherein said
sound-absorbing, insulating, and cushioning film layer comprises
syntactic foam.

6. The sound-muffling tiling system of claim 2, wherein said
sound-absorbing, insulating, and cushioning film layer includes rubber.

7. The sound-muffling tiling system of claim 1, wherein said one
sound-absorbing, insulating, and cushioning film layer comprises a
sequentially rollable composite.

8. The sound-muffling tiling system of claim 1, wherein said one
sound-absorbing, insulating, and cushioning film layer comprises slats.

9. The sound-muffling tiling system of claim 8, wherein said wherein said
slats comprise a tongue-and-groove profile.

10. The sound-muffling tiling system of claim 1, wherein said flooring
base member comprises plywood.

11. The sound-muffling tiling system of claim 1, wherein said flooring
base member comprises medium-density fiberboard.

12. The sound-muffling tiling system of claim 1, wherein said flooring
base member comprises high-density fiberboard.

13. The sound-muffling tiling system of claim 1, wherein said flooring
base member comprises medium-density fiberboard.

14. The sound-muffling tiling system of claim 1, wherein said fastener
comprises glue.

15. The sound-muffling tiling system of claim 1, wherein said fastener
comprises a bonding agent.

16. The sound-muffling tiling system of claim 1, wherein said fastener
comprises an adhesive.

17. The sound-muffling tiling system of claim 1, wherein said flooring
base member and said sound-absorbing, insulating, and cushioning film
layer comprises a square shape.

18. The sound-muffling tiling system of claim 1, wherein said flooring
base member and said sound-absorbing, insulating, and cushioning film
layer comprises a rectangular shape.

19. A sound-muffling tiling system for installing on a planar surface
comprising: at least one sound-muffling tile assembly comprising; at
least one flooring base member comprising high-density fiberboard; at
least one sound-absorbing, insulating, and cushioning film layer
comprising an open cell structure, wherein said open cell structure
comprises reticulated foam, wherein said reticulated foam comprises a
sequential roll; and at least one fastener, said fastener comprising
glue; wherein said at least one flooring base member and said at least
one sound-absorbing, insulating, and cushioning film layer comprise
approximately identical dimensions; wherein said sound-absorbing,
insulating, and cushioning film layer serves to provide a level surface;
wherein said flooring base member and said sound-absorbing, insulating,
and cushioning film layer are secured together via said at least one
fastener; and wherein said sound-muffling tile assemblies are installable
adjacent to one another thereby forming a continuous surface on said
planar surface; and wherein said continuous surface comprising a
plurality of said sound-muffling tile assemblies serve to dampen sound
thereby minimizing sound propagation between living areas.

20. A method of using a sound-muffling tiling system to muffle sound
comprising the steps of: fastening a sound-absorbing, insulating, and
cushioning film layer to the underside of a flooring base member thereby
creating a sound-muffling tile assembly; and installing said
sound-muffling tile assembly on a planar surface adjacent to another said
sound-muffling tile assembly.

[0002] A portion of the disclosure of this patent document contains
material which is subject to copyright protection. The copyright owner
has no objection to the facsimile reproduction by anyone of the patent
document or the patent disclosure, as it appears in the Patent and
Trademark Office patent file or records, but otherwise reserves all
copyright rights whatsoever. 37 CFR 1.71(d).

BACKGROUND OF THE INVENTION

[0003] The following includes information that may be useful in
understanding the present invention(s). It is not an admission that any
of the information provided herein is prior art, or material, to the
presently described or claimed inventions, or that any publication or
document that is specifically or implicitly referenced is prior art.

[0004] 1. Field of the Invention

[0005] The present invention relates generally to the field of floor
tiling systems and more specifically relates to an improved
sound-muffling flooring and tiling system for installation on a planar
surface for dampening sound waves thereby reducing sound from traveling
in various directions when a user travels across the flooring, while also
providing smooth and level surfaces for flooring installation.

[0006] 2. Description of the Related Art

[0007] Members of today's society often live in close quarters to one
another as the world's population is constantly increasing. Consequently,
it is not uncommon for people to share a common dwelling space, living
within close proximity. For example, apartment complexes may provide
multi-level buildings for people to occupy and live on different floors
within a commercial dwelling. Occupants who may live on a level with
other occupants living above may experience noise disturbances when the
upstairs occupants move across their floors. Many times, this results in
noise pollution traveling from floor to floor. This may cause high noise
levels for the individuals living below, which may ultimately cause
headaches, loss of sleep, and other frustrating and inconvenient
conditions. Although individual rooms may be somewhat soundproofed,
floors and ceilings typically cannot due to the lack of soundproofing
products available for the floor installation process.

[0008] Furthermore, sound may travel horizontally thus disturbing
occupants who reside on the same level. For example, a person who is
exercising in a living room may create noise when jumping up and down or
running in place. This sound may travel to other rooms on the same level
and may thus disturb those who are in those rooms. A more effective
solution is needed to dampen and reduce sound waves from
multi-directional travel.

[0009] Various attempts have been made to solve the above-mentioned
problems such as those found in U.S. Pat. No. 7,886,488 to Stephen W.
Payne, Jr. et al; U.S. Pat. No. 6,576,577 to Kenneth B. Garner; U.S. Pat.
No. 7,987,645 to Brandon Tinianov; U.S. Pub. No. 2006/0230699 to James R.
Keene; U.S. Pat. No. 2004/0016184 to Robert J. Huebsch et al; and U.S.
Pat. No. 5,867,957 to James S. Holtrop. This prior art is representative
of sound dampening means. None of the above inventions and patents, taken
either singly or in combination, is seen to describe the invention as
claimed.

[0010] Ideally, a sound muffling system should be lightweight, durable,
reasonably easy to install, and integrally comprise a sound muffling,
leveling and insulating layer. The present invention is designed to
operate reliably and be manufactured at a modest expense. Thus, a need
exists for a reliable sound muffling flooring tile system to provide a
flooring system for ideal use in a multi-story building or dwelling,
wherein this unique flooring system may dampen sound waves produced when
a user moves about thereby minimizing noise travel while also providing
additional insulation and to avoid the above-mentioned problems.

[0012] The general purpose of the present invention, which will be
described subsequently in greater detail, is to provide a novel sound
muffling tile assembly which may comprise a solid base member, a cushiony
foam layer, and a fastening means for securing the foam layer to the base
member. A plurality of assembled sound muffling tiles may then be
installed underneath a floor, which may serve to dampen and limit sound
from traveling when a user moves about the floor. Furthermore, the
cushiony foam layer of the present invention may serve as an insulator
and as a leveler. As an insulator, the film layer of sound muffling tile
assembly may help retain heat or cool air within a room.

[0013] The cushiony film layer of the present invention may comprise a
flexible foam or rubber substrate. In one embodiment, the cushiony film
layer may comprise reticulated foam. Furthermore, the base member may
comprise a hard substrate such as plywood or a medium-density or
high-density fiberboard. In its contemplated ideal use, the sound
muffling underlay tile may serve to reduce noise from traveling between
floors of a residential or professional building as a consequence of the
cushiony film layer which serves as a sound wave dampener. Sound waves
caused by movement on a floor may be obstructed from traveling to the
floor beneath by the foam layer. The cushiony film layer may be securely
attached to the base member via a fastening means. In one embodiment, the
fastener may be glue. However, in other embodiments, the film layer may
be otherwise attached to the base member via a double-sided adhesive or
other suitable equivalent bonding may be used.

[0014] The present invention holds significant improvements and serves as
a sound muffling flooring underlay tile systems. For purposes of
summarizing the invention, certain aspects, advantages, and novel
features of the invention have been described herein. It is to be
understood that not necessarily all such advantages may be achieved in
accordance with any one particular embodiment of the invention. Thus, the
invention may be embodied or carried out in a manner that achieves or
optimizes one advantage or group of advantages as taught herein without
necessarily achieving other advantages as may be taught or suggested
herein. The features of the invention which are believed to be novel are
particularly pointed out and distinctly claimed in the concluding portion
of the specification. These and other features, aspects, and advantages
of the present invention will become better understood with reference to
the following drawings and detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The figures which accompany the written portion of this
specification illustrate embodiments and method(s) of use for the present
invention, sonic foam-enhanced underlay board for the sound-muffling
flooring underlay tile system, constructed and operative according to the
teachings of the present invention.

[0017]FIG. 2 is an exploded view illustrating the sound-muffling tile
assembly comprising a flooring base member and a cushioning film layer
which may be secured together via a fastener.

[0018]FIG. 3 is a perspective view illustrating the sound-muffling tile
assembly wherein the cushiony film layer comprises slats, and the
assembly comprises a tongue-and-groove profile, according to an
alternative embodiment of the present invention of FIG. 1.

[0019]FIG. 4 is a perspective view of an interior of a two-story
residence not using the present invention.

[0021]FIG. 6 is a flowchart illustrating a method of use for the present
invention of FIGS. 1-3 and 5.

[0022] The various embodiments of the present invention will hereinafter
be described in conjunction with the appended drawings, wherein like
designations denote like elements.

DETAILED DESCRIPTION

[0023] As discussed above, embodiments of the present invention relate to
a sound-muffling system and more particularly to a sound-muffling
flooring underlay tile system used to provide an additional sound barrier
between floors within the same dwelling to inhibit the noise disturbance
and sound pollution between individuals sharing a common commercial
building or residence. In turning now to the drawings there is shown in
FIG. 1, sound-muffling flooring underlay tile systems 100 in assembled
condition 150 according to an embodiment of the present invention.
Sound-muffling flooring underlay tile systems 100 may generally comprise
sound-muffling tile assembly 110 which may be installed underneath a
floor surface. Sound-muffling tile assembly 110 may comprise flooring
base member 115, cushioning film layer 120, and fastener 130. In
assembled condition 110, sound-muffling tile assembly 110 serves as a
flooring underlay tile which may be optimally be installed with multiple
sound-muffling tile assemblies 110 along a planar flooring surface. The
present invention may be pre-assembled and in other embodiments may not.

[0024] In continuing to refer to FIG. 1, flooring base member 115 may
comprise a hard, finished composite having a substantially planar surface
and may be cut/manufactured in the shape of a rectangle or square. In one
embodiment of sound-muffling flooring underlay tile systems 100, flooring
base member 115 may comprise plywood 160. It should be noted that
flooring base member 115 and cushioning film layer 120 comprises
substantially approximate dimensions for when adhering them together for
installation.

[0025] As further shown in FIG. 1, cushioning film layer 120 of
sound-muffling tile assembly 110 may comprise a flexible composite
comprising sound dampening and insulating characteristics. In a preferred
embodiment of sound-muffling flooring underlay tile systems 100,
cushioning film layer 120 may comprise foam 155. Foam 155 may comprise an
open cell structure, such as reticulated foam, which may serve to muffle
sound waves and provide insulation. Open-cell structured foams contain
pores which may be connected to each other and form an interconnected
network that is soft, flexible, and durable. For example in one
embodiment of sound-muffling flooring underlay tile systems 100, foam 155
may comprise foam-rubber which may comprise an open-cell structure form.

[0026] In another embodiment of sound-muffling flooring underlay tile
systems 100, foam 155 may comprise closed-cell foam, such as syntactic
foam. Closed-cell foam may integrally comprise hollow particles embedded
in a matrix material. One main advantage of syntactic foams is that they
have a very high strength-to-weight ratio. Although open-cell structure
is lighter in weight, the increased density of closed-cell foam may serve
to further muffle sound from transferring through sound-muffling tile
assembly 110 when in assembled condition 150 as shown in FIG. 1 as well
as provide increased insulation characteristics. Depending on the
application either foam structure may be used. It should be appreciated
that the present invention is designed to meet building code such that
its construction inhibits fire.

[0027] In referring now to FIG. 2, illustrating tile assembly exploded
view 200 of sound-muffling flooring underlay tile systems 100.
Sound-muffling tile assembly 110 may comprise flooring base member 115,
cushioning film layer 120, and fastener 130. As shown, a bottom surface
of cushioning film layer 120 is attachable to a top planar surface of
flooring base member 115 via fastener 130. In the embodiment of the
present invention shown in FIG. 2, flooring base member 115 may comprise
fiberboard 230. It should be noted that fiberboard 230 may comprise
high-density or medium-density fiberboard 230 for varying needs and
applications. Cushioning film layer 120 may comprise foam 155 as shown
and discussed in FIG. 1.

[0028] In still referring to FIG. 2, fastener 130 may comprise adhesive
fastener 220. Adhesive fastener 220 may comprise a double-sided adhesive
with bonding force sufficiently strong to securely attach cushioning film
layer 120 to flooring base member 115. As further illustrated in FIG. 2,
sound-muffling tile assembly 110 may be installed underneath floor 205 in
such a manner that floor 205 is floated (and/or leveled) by cushioning
film layer 120 comprising foam 155. It should be noted that cushioning
film layer 120 may comprise a sequentially rollable composite for ease of
installation.

[0029] In referring now to FIG. 3, illustrating a perspective view of an
alternative embodiment of sound-muffling flooring underlay tile systems
100.

[0030] As shown, sound-muffling flooring underlay tile systems 100 may
comprise slatted tile assembly 300. This embodiment may comprise foam
strips 310 which may be attached to a top surface of flooring base member
115 via fastener 130. As is further shown in FIG. 3, slatted tile
assembly 300 may comprise tongue-and-groove profile 320. In such a
manner, a tongue of one slatted tile assembly 300 may be connected to a
groove of a second slatted tile assembly 300 via tongue-and-groove
profile 320 for convenient attachment and installation. Foam strips 310
may be attached to top surface of flooring base member 115 via fastener
130, wherein fastener 130 comprises high-strength glue. It should also be
noted that fastener 130 may comprise other equivalent high strength
bonding substance, or other suitable fastening means.

[0031] In referring now to FIG. 4, illustrating sound-muffling flooring
underlay tile systems 100 without (before installing) sound-muffling tile
assembly 110. As shown by way of example of how the present invention is
useful to retard sound propagation, upstairs tenant 420 is walking on
non-sound muffling floor tile 405. As upstairs tenant 420 walks around,
sound waves 410 are created by her footsteps as she moves about her
apartment. Consequently, sound waves 410 travel through flooring
substrate 400 comprising non-sound muffling floor tile 405 and into the
living area beneath upstairs tenant 420. As a result, sound waves 410 may
be heard by downstairs tenants 425, as shown in FIG. 4 and may result in
noise disturbance leading to difficulty sleeping, working, reading, and
enjoying a domicile with quiet enjoyment. Landlords may find use with the
present invention to minimize complaints from tenants 425.

[0032] Referring now to FIG. 5, illustrating sound-muffling flooring
underlay tile systems 100 in an `in use` condition 150 according to an
embodiment of the present invention of FIG. 1.

[0033] As shown, upstairs tenant 420 is walking on flooring substrate 400
comprising sound-muffling tile assembly 110. As upstairs tenant 420 moves
around, sound waves 410 created by her footsteps are muffled as they pass
through flooring substrate 400. As shown in FIG. 5, sound waves 410 that
travel through sound-muffling tile assembly 110 comprising cushioning
film layer 120 flooring substrate 400 convert into dampened sound wave
510 when entering the living area beneath upstairs tenant 420. It should
be appreciated that dampened sound wave 510 may be largely inaudible to
downstairs tenants 425 as a result of sound wave 410 passing through
cushioning film layer 120 of sound-muffling tile assembly 110. When
compared to FIG. 4, the reader is able to see the inherent improvement
over existing systems with respect to minimized sound propagation.
Further the present invention also serves to level flooring surfaces.

[0034] As previously mentioned, sound-muffling flooring underlay tile
systems 100 is a sound-muffling and noise-dampening tile underlay system
which may be installed underneath a floor surface for reducing noise
transfer between rooms and between floors within a building or dwelling.
Sound-muffling flooring underlay tile systems 100 may comprise
sound-muffling tile assembly 110. Sound muffling tile assembly 110 may
comprise flooring base member 115, cushioning film layer 120, and
fastener 130. Flooring base member 115 and cushioning film layer 120 may
comprise approximately identical dimensions. In assembled condition 150,
bottom surface of cushioning film layer 120 is attachable to a top planar
surface of flooring base member 115 via fastener 130. Cushioning film
layer 120 may comprise foam 155. Foam 155 may comprise an open cell
structure, such as reticulated foam, which may serve to muffle sound
waves and provide insulation. Open-cell structured foams contain pores
which may be connected to each other and form an interconnected network
that is soft, flexible, and sufficiently durable. In one embodiment of
sound-muffling flooring underlay tile systems 100, foam 155 may comprise
foam-rubber which may comprise an open-cell structure form. Flooring base
member 115 may comprise plywood 160. Fastener 130 may comprise adhesive
fastener 220 for adhering cushioning film layer 120 to flooring base
member 115. Alternatively, sound-muffling flooring underlay tile systems
100 may comprise slatted tile assembly 300 comprising a plurality of foam
strips 310 attached to a top surface of flooring base member 115. It
should be noted that slatted tile assembly 300 may comprise
tongue-and-groove profile 320 for ease of inter-connecting.

[0035] A kit may be provided for sale of the present invention. Upon
reading this specification, it should be appreciated that, under
appropriate circumstances, considering such issues as design preference,
user preferences, marketing preferences, cost, structural requirements,
available materials, technological advances, etc., other kit contents or
arrangements such as, for example, including underlays, fasteners such as
adhesives or the like, different flooring combinations, parts may be sold
separately, etc., may be sufficient.

[0036]FIG. 6 shows flowchart 650 illustrating method of use 600 of
sound-muffling flooring underlay tile systems 100 according to a
preferred embodiment of the present invention of FIGS. 1-3 and 5. Method
of use 600 may comprise the steps of: step one 601 fastening cushioning
film layer 120 to an underside of flooring base member 115 via fastener
130, and step two 602 installing sound-muffling tile assembly 110 along a
planar surface underneath floor 205.

[0037] It should be noted that the steps described in the method of use
can be carried out in many different orders according to user preference.
Upon reading this specification, it should be appreciated that, under
appropriate circumstances, considering such issues as design preference,
user preferences, marketing preferences, cost, structural requirements,
available materials, technological advances, etc., other methods of use
arrangements such as, for example, different orders within
above-mentioned list, elimination or addition of certain steps,
installing pre-assembled systems, installing non-preassembled systems,
including or excluding certain maintenance steps, etc., may be
sufficient.

[0038] The embodiments of the invention described herein are exemplary and
numerous modifications, variations and rearrangements can be readily
envisioned to achieve substantially equivalent results, all of which are
intended to be embraced within the spirit and scope of the invention.
Further, the purpose of the foregoing abstract is to enable the U.S.
Patent and Trademark Office and the public generally, and especially the
scientist, engineers and practitioners in the art who are not familiar
with patent or legal terms or phraseology, to determine quickly from a
cursory inspection the nature and essence of the technical disclosure of
the application.